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Owner’s Manual

Bergey Windpower Co. 2200 Industrial Blvd. Norman, OK 73069 TEL: 405-364-4212 Fax: 405-364-2078

E-mail: [email protected] Web Site: www.bergey.com

Bergey EXCEL 5 Grid-Intertie

Wind Turbine &

Powersync II Inverter

Rev. 3 August, 2012

BERGEY EXCEL 5 SPECIFICATIONS

PERFORMANCE START-UP WIND SPEED……………………………………………. 5 mph (2.2 m/s) CUT-IN WIND SPEED………………………………………………... 4.5 mph (2 m/s) RATED WIND SPEED……………………………………………...… 25 mph (11 m/s) AWEA RATED POWER (at 11 m/s or 25 mph) ……….…. 5.53 kW AWEA ANNUAL ENERGY (at 5 m/s average) ……………. 9,920 kWh CUT-OUT WIND SPEED………………………………………..…… none FURLING WIND SPEED……………………………………………… 31-45 mph (14-20 m/s) MAXIMUM DESIGN WIND SPEED………………………….…. 134 mph (60m/s) PEAK POWER…………………………………………………………... 6.7 kW ROTOR SPEED……………………………………………………….... 0-400 RPM

MECHANICAL TYPE………………………………………………………………………… 3-Blade Upwind, Horizontal-Axis ROTOR DIAMETER……………………………………………………. 20.3 ft (6.2m) WEIGHT……….…………………………………………………….……. 772 lbs (350 kgs) GEARBOX …………………………………………………………….…. none BLADE PITCH CONTROL……………………………………..….... none OVERSPEED PROTECTION………………………………….….... AUTOFURL® TEMPERATURE RANGE…………………………………………… -40 to 140 deg. F (-40 to 60deg. C)

ELECTRICAL OUTPUT FORM………………………………………………..…….. 240VAC, 1-Phase, 60Hz or 220VAC, 1-Phase, 50Hz GENERATOR ………………………………………………………….. Permanent Magnet Alternator POWER PROCESSOR …………………………………………..…. Powersync II Inverter

Owner’s Manual BWC EXCEL 5

Turbine

INTRODUCTION This manual contains important information concerning your Bergey EXCEL 5 wind turbine system and its operational characteristics. We strongly recommend that you read and familiarize yourself with its contents. At several points in this manual items of special interest or significant impact are highlighted by one of the following symbols:

DANGER Hazards or unsafe practices that could cause personal injury or death. WARNING Hazards or unsafe practices which could cause product damage. NOTE Significant points of interest.

Serial Numbers

Each Bergey EXCEL 5 wind turbine has a serial number located on the alternator, near the rear bearing attachment bolts. The mainframe serial number is stamped adjacent to the port cover. The turbine serial number can also be found on the outside of the shipping carton and on the warranty registration card. We recommend that the serial number be copied to this manual for possible future reference. Bergey EXCEL 5 Alternator Serial No.: ________________________ Bergey EXCEL 5 Mainframe Serial No.: ________________________ The Powersync II inverter has a serial number label on its right side. We recommend that this serial number also be copied to this manual. Powersync II Serial No.: __________________________

Owner’s Manual Bergey EXCEL 5 Turbine

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Table of Contents Section Title Page No.

1 System Description 4

A. Rotor System 5 B. Alternator 5 C. Mainframe 5 D. Slip-Rings and Brushes 5 E. Tail Assemble and AutoFurl® Operation 6 F. Spinner and Nacelle 6 G. Powersync II Inverter 6

2 System Operation 7 A. Normal Operation 7 B. High Winds - AutoFurl® 8 C. Unloaded Operation 8 D. Powersync II Inverter 9

3 Installation 12

A. Bergey EXCEL 5 Wind Turbine and Tower 12 B. Fused Disconnect Switch 12 C. Wire Sizes 12 D. Powersync II Inverter 12

4 Inspections and Maintenance 14

5 Trouble-Shooting Problems 16

6 Appendix 19

A. Warranty 20 B. Warranty Registration 21

C. Vendor’s Manual for Powersync II inverter 22


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1. SYSTEM DESCRIPTION

The Bergey EXCEL 5 is an upwind horizontal-axis wind turbine designed for distributed generation applications, connected to the power grid on the customer’s side of the utility meter. The complete unit consists of the following major components, as shown in the figure below: 1. Spinner 6. Slip-ring and Brushes 2. PowerFlex® Blades 7. Tail Assembly 3. Alternator 8. Nacelle Assembly 4. Mainframe 9. Powersync II Inverter 5. Yaw Bearing

1

3

2

5

4 7

6

8

9


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A. ROTOR SYSTEM

The rotor system consists of three PowerFlex® fiberglass blades. Acting like aircraft wings, the blades convert the energy of the wind into rotational forces that drive the alternator. The PowerFlex® blades are rigidly attached to the alternator and they are fixed pitch. The EXCEL 5 rotor blades have a proprietary airfoil, the BWC-7, which was custom designed to provide high efficiency and low noise. The blades for the EXCEL 5 are extremely strong because they are made in a “pultrusion” process that puts more high-strength glass fibers in the structure than any other molding technique. This contributes to their long life and toughness. Blade sets are carefully matched for balance at the factory to ensure smooth operation of the wind turbine. Each blade has a serial number inscribed on its root pad at the inboard end.

B. ALTERNATOR

The alternator converts the rotational energy of the rotor into electricity. The alternator utilizes permanent magnets and has an inverted configuration in that the outside housing rotates, while the internal windings are stationary. It was specifically designed for the Bergey EXCEL 5 and produces power at low speeds, eliminating the need for a speed-increasing gearbox. Since it uses permanent magnets, the alternator is generating voltage whenever the rotor is turning. DANGER The output wiring of the BWC EXCEL 5 presents shock hazard whenever the rotor is turning. Caution must be exercised at all times to avoid electrical shock.

C. MAINFRAME

The mainframe is the structural backbone of the wind turbine. It serves as the attachment point for the yaw bearing and the housing for the yaw-axis slip-ring brushes. The yaw-axis is the full 360 degree pivot that allows the turbine to freely align itself to the wind direction.

D. SLIP-RINGS AND BRUSHES

The slip-rings and brushes conduct the electricity generated in the alternator from the moving (as it orients with the direction) wind turbine to the fixed tower wiring. The slip-rings are


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enclosed in a metallic housing to help protect them from lightning.

E. TAIL ASSEMBLY AND AUTOFURL OPERATION

The tail assembly keeps the rotor aligned into the wind at wind speeds below approximately 31 miles per hour (14 m/s). At about 31 mph the AutoFurl® action begins to turn the rotor away from the wind to limit the rotor speed in high winds. The tail appears to fold, but in reality the tail stays stationary as the rotor turns sideways to the wind. The rotor furls to a maximum angle of 75 degrees (limited by rubber tail stops), so that the unit continues to produce power in high winds. When the high winds subside, the AutoFurl® system automatically restores the turbine into the normal straight position. The rotor continues to spin even in very high winds and this actually makes the blades stiffer. The AutoFurl® system works whether the Powersync II inverter is on or not. Unlike many other turbines designs, the Bergey EXCEL 5 can operate safely without an electrical load connected to the turbine.

F. SPINNER AND NACELLE

The spinner (nose cone) and nacelle provide additional weather protection for the bearings and the slip-ring assembly. The nacelle also improves lightning protection.

G. Powersync II Inverter

The UL-approved Powersync II inverter converts the “variable AC” from the Bergey EXCEL 5 turbine into utility grade electricity so that it can be connected to the wiring in your home. This conversion requires sophisticated electronics and is designed to operate automatically. The Powersync II has a digital display that provides information on the status of the system, its current output power, and its cumulative energy production.


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2. SYSTEM OPERATION

A. NORMAL OPERATION

The Bergey EXCEL 5 produces utility compatible power in the form of 240VAC, 60 Hz, single phase electricity (208 VAC/60Hz and 220 VAC/50 Hz options are available). It is connected through the Powersync II inverter to the utility distribution network in the same manner as household appliances. When the wind speed is too low to operate the wind turbine, all of the electrical power needed for the home will be supplied by the utility company. During these idle periods the Powersync II will consume approximately 0.3 kilowatt-hours of electricity per day. When the system begins producing power, the amount of power which must be purchased from the utility is reduced by an amount equal to the output of the wind system. From the perspective of the utility company the wind system output reduces the electrical load they have to supply, just as if you turned off lights and appliances. The output of the wind system fluctuates with the speed of the wind so the instantaneous amount of electricity being saved will be constantly changing. Quite often your home will be served simultaneously by the utility and your Bergey wind turbine. When the output of the wind system exceeds the power requirements of the house the excess electricity is sold back to the utility. Both the consumer’s right to interconnect a wind system and the utilities obligation to purchase excess power are prescribed by federal law (PURPA, Section 210). The amount you will be credited or paid for this excess production varies state-to-state and sometimes utility-to-utility. If your utility company offers “net metering” then your meter is allowed to turn backwards so that you essentially bank energy, at full value, for less windy periods. This banking can be done over a month or over a year depending on the policy of your state or your utility. If you do not get “net metering” then you will have a second utility meter to register excess production and your utility will pay or credit you for this, typically at less than full value. If your utility experiences an outage (blackout) the wind system will cease to produce power so that it does not present an electrical safety hazard to utility repair crews. Although the wind turbine will continue to operate, no power will be transferred from the Powersync II inverter to your circuit breaker panel. When utility power is restored, the Powersync II will automatically return the wind system to full working status following a five minute delay and then a two minute countdown. These time delays are dictated in the UL standards required by the utilities. The rotor of the EXCEL 5 should begin to rotate when the wind speed reaches approximately 4.5 mph (2 m/s). Once started, the rotor may continue to turn in winds below 4.5 mph (2 m/s),


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but the system will not be producing power below this wind speed. NOTE All operational wind speeds given assume steady winds, sea-

level conditions and moderate temperatures. Hot weather, high altitude, turbulence and gusting winds will reduce system performance.

The rotor speed will increase with increasing wind speed and the system will produce a higher output. This output increases rapidly because the energy available in the wind varies as the third power (cube) of the wind speed. For example, if the wind speed increased from 5 mph to 10 mph, a factor of two, the energy in the wind would increase from one unit to eight units, a factor of eight (2 to the 3rd power). One result of this relationship is that there is very little energy available in light winds. For the average site, winds in the range of 12-20 mph (5.5 – 9 m/s) will provide most of the system’s energy production on an annual basis.

B. HIGH WINDS - AUTOFURL®

During periods of high wind speeds the AutoFurl® system will automatically protect the wind turbine. Furling means that the rotor is turned away from the wind. When furled, the power output of the turbine will be reduced. In winds between 31 mph (14 m/s) and 45 mph (20 m/s) it is normal for the turbine to repeatedly furl and then unfurl and then furl again. During intermittent cycling the turbine may produce output surges up to approximately 6,600 watts.

C. UNLOADED OPERATION

If an abnormal condition occurs on the utility line, such as a voltage fluctuation or a complete interruption, the Powersync II inverter will automatically disconnect the wind turbine from the power grid. If sufficient wind is present, the rotor will continue to operate. Since it is unloaded it will spin at a higher speed and some increase in blade sound is to be expected. This is a perfectly safe and permissible condition as the AutoFurl system will continue to protect the turbine.

DANGER During unloaded operation the alternator can still generate high voltages, so the EXCEL 5 electrical system should be handled with the same caution used during normal operation.

In order to enhance the systems reliability, the power output of the EXCEL 5 is limited to


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approximately 6.6 kilowatts. Since this output is reached at 31 mph (14 m/s), the rotor will become progressively unloaded as wind speeds increase up to the maximum furling point of approximately 45 mph (20 m/s).

D. POWERSYNC II INVERTER The Powersync II inverter is connected to the household circuit through a dedicated 40 amp breaker. Before opening the Powersync II enclosure, the breaker must be turned off and the tower disconnect switch must be switched OFF, to avoid electrical shock.

DANGER Always remember that the system operates at 240 volts, so electrical shocks can be fatal!

Using the utility grid as a reference, the Powersync II inverter converts the output of the wind turbine into utility-compatible alternating current (AC). The Powersync II inverter has been designed for automatic, unattended operation and it is programmed to provide maximum performance from your Bergey EXCEL 5 wind turbine. It is also programmed to safely disconnect the wind turbine in the event of a problem with the utility power and to automatically reconnect the turbine after the problem is remedied. The LCD digital display on the front of the Powersync II provides information on the status of your Bergey EXCEL 5 wind turbine. The contrast can be adjusted UP or DOWN using hidden buttons on the right side of the display.

In normal operation the Powersync II will show the status as “Running” and will display the instantaneous Output Power in Watts. Other operating modes that may be indicated are as follows:


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Using the Up and DOWN arrows you can scroll through the additional Powersync II information available, as shown below.

When the Powersync II is starting up after initialization, or after the RESET button has been pushed, or after a power outage, it will go through a 300 second (5 minute) countdown that is required by UL 1741. This UL standard also dictates high and low limits for utility voltage and frequency, outside of which the inverter is required to shut down until they return to the acceptable range. This is called a FAULT condition. There are a number of possible FAULT conditions during which the Powersync II will be protecting itself or the power grid. When a FAULT occurs the Powersync II will shut down (no power production) and a Fault Code will be displayed on the digital display. A list of the Fault Codes can be found in the detailed instructions for the Powersync II inverter provided in the


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Appendix. FAULTS will reset themselves automatically; assuming the underlying cause of the fault has been cleared, unless the inverter experiences three (3) FAULTS of any type in a one hour period. In this case a manual RESET is required on the digital display.

CAUTION If a manual reset is required we highly recommend that you check the FAULT CODE list for indications that there is an equipment or wiring problem that needs addressing.

One unique feature of the Powersync II inverter is its Soft Grid power limiting capability that can reduce the number of nuisance FAULTS on weak power lines during periods of high turbine power output. On a weak power line the EXCEL 5 wind turbine can, on a windy day, raise the local utility voltage above the UL 1741 threshold, causing a FAULT. The Soft Grid feature tries to prevent these FAULTS by reducing power output from the wind turbine. When the Powersync II is in this mode the digital display will show “Soft Grid”. The STOP pad on the digital display will shut down the Powersync II inverter. Press the RESET pad to restart (which will start the 300 sec. countdown). If the circuit breaker in your home or business load center (circuit breaker panel) trips, it should be reset by first switching it to the OFF position and then to the ON position. If the breaker trips again immediately, or if it continues to trip after brief periods of normal operation, switch the breaker OFF and contact your Bergey dealer for assistance. The following recommendations will help ensure the safe operation of the Powersync II inverter:

1. Keep all sources of moisture away from the Powersync II enclosure.

2. Do not work near the Powersync II with gasoline, paint thinner, or any material which produces flammable vapor. Do not store flammable materials near the Powersync II enclosure.

3. Do not open the Powersync II enclosure unless the circuit breaker and Accessible Disconnect Switch (ADC) at the base of the tower have been switched OFF. Note that even with the circuit breaker and ADC switched OFF, a shock hazard will still be present inside the Powersync II enclosure for approximately 15 minutes (as the capacitor voltage drains down).

4. Do not block airflow around the Powersync II enclosure in any way. A six-inch clearance must be maintained around the sides, top, and bottom of the enclosure for adequate air circulation.


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3. INSTALLATION Please use the following instructions in assembling and commissioning your system. If you need any additional information, please contact us.

A. BWC EXCEL 5 WIND TURBINE and TOWER

Please refer to the BWC EXCEL 5 Installation Manual, and any addendum for the specific tower design, for instructions on installing the wind turbine and tower.

B. FUSED DISCONNECT SWITCH

The electrical output of the wind turbine is a three-phase alternating current (AC). We strongly recommend the installation of a fused three-phase AC disconnect switch between the wind turbine and the Powersync II, as shown in the drawing on Page 16. This switch is commonly referred to as an Accessible Disconnect Switch (ADC) and most utilities will require one to be installed. A 60A weather-tight switch box with 45A fuses for the 240 VAC, 60Hz or 220VAC, 50Hz system is recommended. The fuses will help protect the alternator in the event of a wiring, controller, or load short circuit. The fused disconnect switch is normally installed at the base of the tower. CAUTION Do not install a permanent “short circuiting switch” that will

provide dynamic braking of the alternator. These switches can be easily misused, leading to serious damage to the alternator. Such damage is not covered by the BWC warranty.

C. WIRE RUN AND WIRE SIZES

Please refer to the BWC EXCEL 5 Installation Manual for recommended wire and conduit sizes for the tower-to-Powersync II wire run.

D. POWERSYNC II INVERTER

The Powersync II inverter should be installed near the main breaker enclosure if possible. A minimum of six inches of clearance is required on the top, bottom and sides of the Powersync II to ensure adequate air flow through the enclosure.


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The Powersync II should be connected to a dedicated 40A breaker installed in the main breaker box. System grounding is accomplished by attaching a wire, # 8 AWG minimum, from the grounding lug inside the Powersync II enclosure to the panel ground inside the main breaker box. Additionally, the tower “bond” ground wire should be connected to the grounding lug inside the Powersync II enclosure. A typical system wiring schematic for the Bergey EXCEL 5 is shown below. The three AC connections from the wind turbine can be connected to the Powersync II terminals in any order; there is no required phase orientation.

DANGER Do not attempt to make the Powersync II connections with energized leads. Always have the wind turbine fully disconnected and the circuit breaker switched to “off” before making the Powersync II connections.

All wiring should conform to the National Electric Code or other governing local electrical code. The use of electrical conduit for wiring between components is highly recommended. All terminations should be coated with an anti-oxidation compound to prevent corrosion. CAUTION All loads should be equipped with fuses or circuit breakers to

avoid hazards from accidental short circuits.

10 kW Wind Turbine

24 m (80 ft) GuyedTower

Safety Switch

Power Processing

Unit (Inverter)

Cummulative Production

Meter

AC Load Center


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4. INSPECTIONS AND MAINTENANCE

The Bergey EXCEL 5 turbine and tower should be inspected 30 days after installation, and then again 180 days after installation. Following these two inspections the installation should be inspected every two years and after any particularly severe weather. Inspections should be done on days when the wind is below 16 mph (7 m/s). Check List for Inspections 1. Inspect each of the anchor points. Ensure that all hardware is secure and the guy wires are

properly tensioned. Check to ensure that no strands are broken and the turnbuckle safety cables are in place.

2. Disconnect the inverter and short the alternator using the procedure given in the

installation manuals. Climb the tower. Always use proper safety climbing gear and safe climbing practices.

3. Inspect the blades for: A. Cracks outboard of the hub pad, in the blade pultrusion itself. Cracks in the

molded hub pad are normal after a few weeks of operation and will not affect the strength or reliability of the blade.

B. Condition of the leading edge protection tape. Torn or peeling tape will need replacing.

C. Leading or trailing edge damage. D. Condition of the paint. 4. Remove the spinner and hang it from the machine. Check the torque on the blade nuts;

the recommended value is 150 ft-lbs. Check the front bearing for seal integrity and grease loss. Reattach the spinner and check that it is secure.

5. Remove the side of the nacelle. Hang it from the tower or tail boom while you inspect the

turbine. 6. Check the rear alternator bearing for seal integrity and grease loss. 7. Inspect the mainframe for cracks. 8. Remove the slip-ring cover plate. Make the following inspections:


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A. Check brushes for ease or movement in the brush holder. B. Check slip rings for signs of arcing damage. C. Clean excessive grease from yaw bearing leakage onto the slip-rings. 9. Check for cracks or loose hardware on the tail boom and fin. 10. Check the tail pivot pin and particularly its fasteners. 11. Close the nacelle and check that all of its fasteners are secure. 12. Inspect the integrity of the yaw bearing seal. Add grease if necessary – roughly in

proportion to the grease loss observed. There should be a coating of grease on the seal to improve water tightness.

13. While descending the tower, inspect the following: A. Check that the tower wiring is properly secure. B. Check all fasteners. C. Look for any cracks in the tower structure. D. Check the condition of the guy wire attachment, if present. 14. Check the connection on all ground rods and hardware. 15. Remove the alternator shorting connection. Check the disconnect switch. 16. Switch the disconnect switch to "OFF.” Listen to the sound of the machine as it speeds up.

No mechanical sounds, such as a "clunking" or "banging," should be heard. Also watch for any new or significant vibration. The turbine operation should be smooth.

17. Inspect the wire run, particularly all electrical connections. 18. Check condition of all wiring connections into and out of the Powersync II. 19. Check the fan filters on the Powersync II. 20. At the second annual inspection, and at each alternate inspection thereafter, inspect the

condition of the brushes and internal fasteners.

DANGER Only qualified personnel with proper safety equipment should climb the tower. Never climb the tower when the rotor is turning at a rate greater than 10 rpm.


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5. Trouble-Shooting Problems

The following guide can help to pin-point the cause of operational problems with the Bergey EXCEL 5 wind turbine and the Powersync II inverter For problems or symptoms not found in the following listing please contact the Service Department at Bergey Windpower Co. at Tel. No. 1-405-364-4212, Telefax No. 1-405-364-2078, or E-mail: [email protected]

Problem Cause(s) Diagnosis Remedy Turbine makes an unusual blade sound, such as whistling or buzzing

1. Damaged blade leading edge tape 2. Blade (pultrusion) structural damage

1. Have leading edge tape inspected 2. Have blades inspected. Cracks outboard of the molded hub can lead to blade failure.

1. Replace tape as necessary 2. If blade damage is suspected, the turbine should be inspected. Contact your dealer.

Rotor is unbalanced, causing the turbine to move slightly back and forth as it spins

1. Uneven ice build-up on blades 2. Blade damage

1. Ice on turbine and tower. Turbine ran smoothly before ice storm. Slow rotor speed. 2. No ice. Turbine ran smoothly before

1. Do nothing – ice will dislodge in a few days. 2. If blade damage is suspected, the turbine should be inspected. Contact your dealer.


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Problem Cause(s) Diagnosis Remedy Turbine makes a banging or rattling sound once per revolution, particularly at low speeds

1. Loose spinner 2. Alternator rear bearing ring fasteners loose or missing 3. Alternator bearings

1. More likely on pre-2004 turbines (when design was changed) 2. Requires inspection 3. Excessive grease leakage. Squeaking sounds at low speed.

1. Have spinner inspected 2. Have alternator inspected 3. Have alternator inspected

Turbine makes a “fog horn” sound at certain, typically low, wind speeds

Electro-mechanical interaction between alternator and inverter that causes transient vibrations in the turbine

Sound comes and goes, but occurs at the same wind speed(s)

This is normal, but contact your dealer or the Bergey Service Department if the noise is excessive

Turbine makes a continuous growling or rumbling sound, which reduces at higher wind speeds

1. Wiring fault 2. Inverter fault 3. Alternator bearings

Switch fused disconnect on tower to OFF. If growling disappears an electrical problem is indicated. If growling continues a mechanical problem is indicated 1. Check fuses. Check wiring for continuity, phase-to-phase fault, or short to ground. 2. After completing the wiring check, disconnect the inverter and reconnect wiring to the turbine. If the noise disappears an inverter problem is indicated. 3. Check for excessive grease loss

1. Repair or replace as needed 2. Contact your dealer 3. Have the alternator inspected


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Problem Cause(s) Diagnosis Remedy Rotor turns slowly and does not speed up in higher winds

1. Ice build-up on blades 2. Short circuit in wiring or inverter 3. Short circuit in tower wiring, slip-rings, or alternator

1. Check for ice 2. Open tower disconnect. If turbine spins freely an electrical system problem is indicated 3. The most likely problem is a shorted alternator. Diagnosis requires tower climbing

1. Do nothing – ice will dislodge in a few days. 2. Contact your dealer 3. Contact your dealer

Rotor does not turn at all Mechanical failure inside alternator

Rotor does not turn even when winds exceed 15 mph (6.7 m/s)

Contact your dealer

Powersync II display not functioning

1. No power to inverter 2. Display or other inverter component not functioning properly

1. Turn off utility power to inverter, using the dedicated breaker in your breaker panel, for a minimum of 20 seconds. Then turn power back on using the breaker. Wait 300 seconds (5 minutes). If inverter does not resume operation, with full display functionality, contact your dealer


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Appendix


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Powersync II - 240 VAC (AMFA-35) and

Powersync II - 208 VAC (AMFA-39)

Operator's Manual &

Installation Instructions

Rev. 1.0

Date: 15 July, 2011

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